ONGC experiences with Methane Leak Detection and Measurement Studies The Global Methane Initiative Partnership-Wide Meeting

Transcription

1 ONGC experiences with Methane Leak Detection and Measurement Studies The Global Methane Initiative Partnership-Wide Meeting A B Chakraborty Executive Director- Chief,Carbon Mgt Group Implementation Manager, GMI Program ONGC, India Krakow Oct 13,2011

2 Agenda ONGC measurement study results 2008 study (Collaborative) 2009 study (Collaborative) 2011 study (In- house) Opportunities for ONGC Potential Projects Future Plan Conclusions 2

3 ONGC s measurement study results USEPA and ONGC conducted four onsite measurement studies to assess key methane emission sources and potential mitigation measures (May 2008, Nov 2009) ONGC conducted thro its inhouse team at 24 production facilities in 2011 (as of Oct 2011) 3

4 ONGC s measurement study results In 2008 under USEPA-ONGC collaboration Heera Platform Uran Plant Kalol in Ahmedabad Asset Geleki in Assam Asset 4

5 Summary Results of Measurement Study, May 2008 Total 16.3 million m 3 /year methane emissions URAN PLANT 8,522 thousand m 3 /year 52 percent GELEKI - ASSAM 3,272 thousand m 3 /year 20 percent 5 KALOL - AHMEDABAD 426 thousand m 3 /year 3 percent HEERA PLATFORM 4,061 thousand m 3 /year 25 percent In cases where measurements not possible due to physical access limitations, experts estimated emission rates based on previous measurement experience

6 Summary Results of Measurement Study, May 2008 Top 12 recommended methane recovery projects generate Rs. 311 Lakhs/year from gas value reduce methane emissions by up to 10.8 million m 3 /year Projects also increase production recover natural gas liquids potentially have carbon value use field-proven and commercially available methods implemented by other worldwide operators 6

7 Overall Methane Emissions by Source RECIPROCATING COMPRESSOR ROD PACKING 2,919 thousand m 3 /year 18 percent Compressors, storage tanks, and acid gas removal vents contribute over 80 percent of the 16.3 million m 3 /year TANK VENTS 1,878 thousand m 3 /year 12 percent CENTRIFUGAL COMPRESSORS 3,099 thousand m 3 /year 19 percent FUGITIVES 442 thousand m 3 /year 3 percent VENTS 2,669 thousand m 3 /year 16 percent 7 ACID GAS REMOVAL 5,208 thousand m 3 /year 32 percent WELL VENTING 66 thousand m 3 /year less than 1 percent

8 Heera Platform Site Study Results Platform vent stack contributes over 60 percent of the 4.1 million m 3 /year methane emissions VENT 2,541 thousand m 3 /year 63 percent CENTRIFUGAL COMPRESSORs 1,269 thousand m 3 /year 31 percent 8 FUGITIVES 251 thousand m 3 /year 6 percent

9 Heera Platform Emissions and Revenue Opportunities Emissions Source Platform vents Wet seal oil degassing Mitigation Option Recoverable Methane (Rs./year) Route vented emissions to vapor recovery unit Route vented emissions to vapor recovery unit Equipment leaks Conduct periodic leak survey and repair Payback range based on gas value: to 1.4 years 81 Lakhs 41 Lakhs 8 Lakhs

10 Uran Plant Site Study Results Centrifugal compressor seals, fugitives, and storage tanks contribute 39 percent of the 8.5 million m 3 /year methane emissions ACID GAS REMOVAL 5,208 thousand m 3 /year 62 percent CENTRIFUGAL COMPRESSOR 1,830 thousand m 3 /year 21 percent FUGITIVES 9 thousand m 3 /year <1 percent 10 STABILIZED CRUDE TANKS 268 thousand m 3 /year 3 percent UN-STABILIZED CRUDE TANKS 1,207 thousand m 3 /year 14 percent

11 Uran Plant Emissions and Revenue Opportunities Emissions Source Mitigation Option Recoverable Methane (Rs./year) Centrifugal compressor wet seal degassing Replace wet seals with dry seals 56 Lakhs Un-stabilized crude tank Route vented emissions to vapor recovery unit Stabilized crude tank Route vented emissions to vapor recovery unit 220 Lakhs (as per actual data) 9 Lakhs Payback range based on gas value: 0.2 to 4.0 years 11

12 Kalol Ahmedabad Site Study Results Storage tank, well, and other vents contribute over 85 percent of the 0.4 million m 3 /year methane emissions FUGITIVES 52 thousand m 3 /year 12 percent VENTS 128 thousand m 3 /year 30 percent TANK VENTS 176 thousand m 3 /year 42 percent RECIPROCATING COMPRESSOR ROD PACKING 12 4 thousand m 3 /year 1 percent WELL VENTING 66 thousand m 3 /year 15 percent

13 Kalol Ahmedabad Emissions and Revenue Opportunities Emissions Source Vent stacks Storage tanks Well venting Equipment leaks Mitigation Option Route vented emissions to vapor recovery unit Route vented emissions to vapor recovery unit Install beam gas compressors Conduct periodic leak survey and repair Recoverable Methane (Rs./year) 6 Lakhs 5 Lakhs 3 Lakhs 2 Lakhs Payback range based on gas value: 4.1 to 8.7 years 13

14 Geleki - Assam Site Study Results Reciprocating compressor rod packing contributes 89 percent of the 3.3 million m 3 /year methane emissions RECIPROCATING COMPRESSOR ROD PACKING 2,915 thousand m 3 /year 89 percent 14 FUGITIVE EMISSIONS 130 thousand m 3 /year 4 percent TANK VENTS 227 thousand m 3 /year 7 percent

15 Geleki - Assam Emissions and Revenue Opportunities Emissions Source Reciprocating compressor rod packing Oil storage tanks Equipment leaks Mitigation Option Recoverable Methane (Rs./year) Early replacement of rod packing Route vented emissions to vapor recovery unit Conduct periodic leak survey and repair 55 Lakhs 4 Lakhs 3 Lakhs Payback range based on gas value: to 10 years

16 Summary Results of Measurement Study, Nov 2009 Installation covered: 1. CPF Gandhar 2. Offshore SH Complex 3. Hazira Gas Processing Complex 16

17 CPF Gandhar Over 2.74 million cubic meters (million m 3 ) / year identified for reduction 1. Reciprocating compressor rod packing emissions: 1.78 million m 3 /year 2. Emissions from centrifugal compressor seal oil degassing vents: 0.4 million m 3 /year 3. Tank vent emissions (measured and estimated: 0.35 million m 3 /year 4. Emissions from leaking components: 0.2 million m 3 /year 17

18 Mumbai Offshore SH Complex Over 8.74 million cubic meters (million m 3 ) / year has been identified for capture 1. Vent emissions at 3.89 million m 3 /year (represents emissions from 10" LP Surge Tank and Strip Gas vent) 2. Leaking components emissions at 3.87 million m 3 /year 3. Centrifugal compressor seal oil degassing vent emissions at 0.98 million m 3 /year 18

19 Hazira gas processing complex Over 2.23 million cubic meters (million m 3 ) / year identified for reduction 1. Reciprocating compressor rod packing emissions:.04 million m 3 /year 2. Leaking components emissions: 1.04 million m 3 /year 3. Glycol reboiler vent emissions: 0.15 million m 3 /year 19

20 Measurement study by in-house ONGC team Total 26 facilities covered:(dec 2010-Oct 2011) Ahmedabad Asset: Six Installations Kallol- GGS IV, GGS VII, GGS VIII Nawagam- GGS III & GCP Jalora - GGS I Mumbai Offshore: BHS Complex Neelam Complex Uran Plant Tripura asset: 4 Facilities Assam Asset: 13 Facilities

21 Emissions and Revenue Opportunities- BHS platform Source Quantity (MMSCM/Year) Suggested Mitigation Option Revenue (Rs./year) Equipment leaks 0.86 Conduct periodic leak survey and repair 27.5 Lakhs Platform vents 4.6 Feasible technical solution reqd- e.g. use of screw compressor etc 147 Lakhs Gas value at 3200/thousand m3; assuming 100% mitigation

22 Emissions and Revenue Opportunities- Neelam Platform Source Quantity (MMSCM/Year) Suggested Mitigation Option Revenue (Rs./year) Equipment leaks Conduct periodic leak survey and repair Vents 1.8 Recommend detailed engineering study for thro screw compressor 0.24 Lakhs 57 lakhs Gas value at 3200/thousand m3; assuming 100% mitigation

23 Emissions and Revenue Opportunities- AMD Asset Source Quantity (MMSCM/Year) Suggested Mitigation Option Revenue (Rs./year) Storage tanks (GGS VII, GGS IV, GGS III, GGS I) 0.8 Very Low Tank emission except GGS VIII. Individual tank vapor mitigation not viable GGS VIII 0.55 (Conservative) Vented emissions - vapor recovery unit/ ejector system 24 Lakhs Equipment leaks 0.21 Periodic leak survey based repair 9.2 Lakhs Gas value at 4400/thousand m3; assuming 100% mitigation

24 Emissions and Revenue Opportunities- URAN Plant Source Quantity (MMSCM/Year) Suggested Mitigation Option Revenue (Rs./year) Equipment leaks 0.15 Conduct periodic leak survey and repair 5 Lakhs Tank Vapour 3.3 (Per the actual data) Vapor recovery unit rehabilitated and working 10crores* Gas value at 3200/thousand m3; assuming 100% mitigation *VAP production 40000/T

25 Emission Recovery Potential 7 installations- 30 MMSCM/Yr 9 installations 9 MMSCM/Yr (Emission from other 17 installations not incorporated) Work yet to be undertaken at- More than 100 GGS & GCP

26 Measurements Study Equipments Gas Find IR Camera Turbine meter Vent bags 26

27 Opportunities Directed Inspection & Maintenance (DI&M) Methane leaks are invisible and often go unnoticed Directed Inspection & Maintenance Periodic, directed surveys and measurement Prioritize leaks for repair Fix significant leaks that are cost-effective to repair CONDUCT baseline survey SCREEN and MEASURE leaks FIX on the spot leaks ESTIMATE repair cost, select repairs DEVELOP a plan for future DI&M REPORT savings 27

28 Achievements through DI&M 3.2 MMSCM ( ) 4.7 MMSCM ( ) In 2011 there was no opportunities under DI&M practices 28

29 Opportunities - Reciprocating Compressors Reciprocating compressor rod packing impediments to sealing: Dirt or foreign matter Worn rod Insufficient/too much lubrication Packing cup out of tolerance Determine economic replacement by: Determining new packing leak rate and monitoring increases Determining replacement cost Replacing when leak reduction pays pack cost Geleki - Assam: Replace Reciprocating Compressor Rod Packing Gas Leakage Piston Rod Piston Rod Net First-year Costs: 44 Lakhs Payback: 0.8 years Improper break-in on startup Liquids Incorrect installation Methane Savsg: 2,843 thousand m 3 /year average 29

30 Opportunities - Centrifugal Compressors Centrifugal compressor wet seals emit methane at: Seal face (small emissions) Seal oil degassing sump (large emissions) Dry seals reduce emissions and operating costs Series of rings create high pressure gas barrier Eliminates need for seal oil barrier Uran Plant: Replace Centrifugal Compressor Wet Seals with Dry Seals Net First-year Costs: 119 Lakhs Payback: 0.9 years Methane Savings: 1,742 thousand m 3 /year 30

31 Methane saving potential projects in ONGC thro the use of VRU 1. Kallol CTF Complex Process tanks, Ahmedabad Asset 2. GGS VIII- Ahmedabad Asset 3. Uran: Already implemented 31

32 Future Plan To map all the production installations across ONGC for methane emissions and form a comprehensive fugitive emission inventory of ONGC. To incorporate appropriate technical interventions to reduce these emissions. Yearly monitoring. A system of yearly reporting of methane reductions 32

33 Conclusions Opportunities exist for ONGC Evaluate and implement cost-effective projects Seek to improve project economics through carbon markets Dedicated methane emission identification and measurement team- building capacity Gain recognition for efforts via promotion internally and to external stakeholders Share learning and best practices with other Gas STAR companies (presentations, articles) 33

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